US5745230A - Ophthalmic lens inspection system and method - Google Patents

Ophthalmic lens inspection system and method Download PDF

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Publication number
US5745230A
US5745230A US08/681,639 US68163996A US5745230A US 5745230 A US5745230 A US 5745230A US 68163996 A US68163996 A US 68163996A US 5745230 A US5745230 A US 5745230A
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United States
Prior art keywords
pallet
lens
lenses
containers
unacceptable
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Expired - Lifetime
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US08/681,639
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English (en)
Inventor
Russell J. Edwards
James A. Ebel
Borge Peter Gundersen
Thomas Christian Ravn
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Johnson and Johnson Vision Care Inc
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Johnson and Johnson Vision Products Inc
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    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01J—MEASUREMENT OF INTENSITY, VELOCITY, SPECTRAL CONTENT, POLARISATION, PHASE OR PULSE CHARACTERISTICS OF INFRARED, VISIBLE OR ULTRAVIOLET LIGHT; COLORIMETRY; RADIATION PYROMETRY
    • G01J1/00—Photometry, e.g. photographic exposure meter
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M11/00—Testing of optical apparatus; Testing structures by optical methods not otherwise provided for
    • G01M11/02—Testing optical properties
    • G01M11/0207—Details of measuring devices
    • G01M11/0214—Details of devices holding the object to be tested
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M11/00—Testing of optical apparatus; Testing structures by optical methods not otherwise provided for
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
    • G01M11/00—Testing of optical apparatus; Testing structures by optical methods not otherwise provided for
    • G01M11/02—Testing optical properties
    • G01M11/0207—Details of measuring devices

Definitions

  • the tray containing lenses and saline is transferred to an inspection station attended by a human operator.
  • a viewing assembly is positioned above a first well.
  • the lens in the well is illuminated from below and an image is transferred by the viewing apparatus and projected upon a screen at the inspector's eye-level. The inspector manually varies the field-of-focus to examine different depths of the lens.
  • the human inspector After looking for the appropriate lens characteristics and deviations from accepted standards, the human inspector makes a decision as to whether the lens is acceptable. The inspector often finds it is useful to move or displace the lens slightly relative to the tray well in which it is contained, or to otherwise disturb the saline solution in order to distinguish between foreign particles in the saline and imperfections in the tray well from characteristics or defects of the lens.
  • the inspector enters his decision by pushing the appropriate electrical switch to indicate that the lens is either acceptable or to be rejected.
  • the viewing mechanism then indexes over to the next well in the tray where the inspection procedure is repeated.
  • certain time constraints must be placed upon the inspector such that if a decision is not made within a predetermined amount of time, the lens is automatically considered defective, and the viewing apparatus indexes to the next well.
  • lenses that may otherwise be acceptable but are accompanied by extraneous pieces of foreign material or if two lenses are found in the same well the situation is considered unacceptable and the contents of the well rejected.
  • the inspector Upon the completion of the inspection of an entire tray of lenses, the inspector activates another electrical switch to initiate disposition of the lenses of the tray just inspected.
  • a disposal unit visits each well of the tray where an unacceptable lens was indicated to suction out and dispose of those lenses. The tray is then transferred along for the packaging of the acceptable lenses.
  • an automated inspection system can be implemented where an image of the lens to be inspected is captured using a strobe lamp and a camera and the image then digitized and processed by a computer to make a determination whether the lens is acceptable.
  • Both of these requirements must be met while permitting the lamp and camera to be positioned to allow the camera to capture a high quality image of the lens. It is preferable that the above objectives be achieved while the lamp and camera are on opposite sides of the lens, allowing the light to pass through the lens, an image to be captured by the camera and then digitized. These requirements mandate that the mechanism for holding and moving the lenses be located substantially to the sides of the lens travel path in order not to obstruct the light from the lamp from which the image is captured.
  • a further object of the present invention is to provide a receptacle for receiving one or more contact lens containers that can then be transported by a conveyor to an inspection station comprising the lamp and camera.
  • a lens pallet is provided having wells for receiving one or more lens containers at the receiving point.
  • the conveyor of the present invention achieves the requisite uniformity of motion needed in the direction of pallet travel and stability when transporting the lens in the orthogonal, non-translating directions by use of one or more guide rails.
  • the pallet is restrained between the rails, except in the direction of travel, by mechanical bias means such as spring-loaded roller balls located on the side walls of the pallet body which cooperate with guide rails on the conveyor positioned to compress the mechanical bias means when the pallet is between the guide rails.
  • Engagement means on the pallet are also provided for engaging a drive means which transports the pallet through the inspection station.
  • the pallet is restrained against a single guide by means of the drive device.
  • the device moves against the guide rail by means of an L-shaped arm.
  • the drive means is then activated and allows the L-shaped arm to slide along the pallet edge. As the arm slides, it engages the rear edge of the pallet and pulls the pallet in the desired direction of travel for inspection.
  • the pallet wells for receiving the containers comprise holes that pass through the pallet. These holes along with the above-described guide and transport system make possible an arrangement of the lamp and camera for capturing an image of a lens that maximizes utilization of the field-of-view of the camera and minimizes blurring.
  • a computer implemented algorithm then processes the digitized image according to rules set forth in a computer program to determine the acceptability of the lenses.
  • a lens disposition mechanism connected to the computer uses a signal generated by the computer and indicates the lens acceptability determination to disposition the lens by physically separating an acceptable lens from an unacceptable lens.
  • the containers holding the lenses are removed from the pallet and sent along different paths so that a failure to remove a container from the pallet does not result in the passing of an unacceptable lens.
  • the pallet is returned by conveyor to the lens receiving point.
  • FIG. 1 is a top planar flow schematic of the apparatus of the present invention shown in relationship with associated equipment.
  • FIG. 2 is an elevational planar view of an apparatus constructed according to the present invention shown as a top planar view.
  • FIG. 3 is a side elevational planar view of the apparatus of FIG. 2.
  • FIG. 4 is an end elevational planar view of the apparatus of FIG. 3.
  • FIG. 1 shown is the present invention in relationship with the apparatus preceding and following the inspection apparatus of the present invention.
  • Lenses are received from a hydration line 10 wherein the lenses produced are hydrated by repeated or extended exposure to deionized water.
  • the hydration apparatus and process are, respectively described more fully in U.S. Pat. Nos. 5,094,609 and 5,080,839.
  • the lenses within the hydration chambers travel down line 12 which delivers the lenses in the chambers to a pick and place unit 14, of the type such as the Adept One Industrial Robot, made by Adept Technology, San Jose Calif.
  • This pick and place unit 14 removes the lenses from the hydration chambers and places them into containers (not shown) residing on a transport pallet
  • the lenses then travel in the container on the pallet down track 18 until they arrive at a second pick and place unit 20.
  • This unit is of the type such as the Hauser Motion Control HLE 80 (Upper St. Clair, Pa.) for horizontal movement and Festo Corp. Rotating Cylinder, DSR-25-180-P, Hauppauge, N.Y. for vertical movement.
  • the pallets are removed from track 18 and placed into an inspection station 22. If preferred, a buffer unit may be added between the lens loading area and the inspection station to accommodate different operating rates of the twounits.
  • the inspection station 22 comprises a conveyor for transporting the pallet 24 to inspection points 26 and 28. Because the wells on the pallet are located in two parallel rows, the inspections are performed independently on the two rows of lenses contained on the pallet 16 by inspection stations 26, 28.
  • the inspection station 22 is isolated from the remainder of the automated inspection apparatus in order to eliminate adverse interactions between the inspection station and the remainder of the system that could be induced by mechanical vibrations associated with the remainder of the system.
  • a computer implemented algorithm then processes the image captured at the inspection points 26, 28 according to rules set forth in a computer program to find the non-conformities in the lens and therefrom determine the acceptability of the lenses.
  • conveyor 24 delivers the pallet to a third pick and place unit 30 which removes the pallets from the inspection station 22 and places it upon another transport system 32.
  • Thispick and place unit is of the same type as 20.
  • the pallet containing the inspected lenses moves along transport system 32 to a deionized water removal station 34. Because deionized water is not isotonic with human eye tear fluid (does not have the same salt concentration), it is necessary that the deionized water be removed. As the pallet moves along transport system 32 it encounters a lens disposition mechanism which is a fourth pick and place unit 36 which receives a signal from the appropriate inspection station 26 or 28 indicating the acceptability of the inspected lens. This pick and place unit 36 is of the same type as unit 14.
  • Containers which serve as the final package containing lenses, are dispositioned by the lens disposition mechanism 36 by removal from the pallet.
  • Containers holding unacceptable lenses are dispositioned by being placed on a rejection conveyor 40.
  • This rejection conveyor causes the containers holding unacceptable lenses to travel down path 40 and into disposal bin 42.
  • Those packages with acceptable lenses are dispositioned by being transferred to an accumulation rail 38.
  • This rail acts to consolidate the packages with acceptable lenses, closing any spaces between packages left by those removed for having unacceptable lenses.
  • This area also serves as a buffer to compensate for variations in final output.
  • the now empty pallet moves to a return conveyor 44 where it encounters a container loading station 46.
  • Containers are injection molded, for example of polypropylene, at the molding station 48 and transported to station 46 to be loaded into the pallets. As the pallets return on conveyor 44 they are dosed with deionized water then proceed to the beginning of the pallet routing process described above.
  • a buffer may be provided between the point where pallets are emptied and returned in order to match unit requirements.
  • lenses are routed to aloading station 50 and then travel to a saline dosing station 52 where the appropriate concentration of salt solution is deposited in each package, all of which now contain an acceptable lens. This may be done by adding the appropriate amount of concentrated saline solution to the deionized water, adding an amount of salt, or removing the deionized water and adding saline solution.
  • the container then travels to a covering station 54 where plastic coated foil is cut and placed upon the lens-containing package.
  • the package After further travel to station 56, the package is sealed by heating the plastic coated foil in a conventional manner to melt the plastic and provide a hermetic seal around the periphery of the package.
  • the packaged contact lenses After final travel to station 58, the packaged contact lenses are sent on to be sterilized, placed into secondary packages and sent to inventory.
  • inspection station 22 is shown in mechanical detail from a top elevational planar view with like elements having like identification numerals. Identified in this drawing is pallet 16 and guiderails 60 which contain the pallet therebetween. Also discernible in this figure are the individual holes 62 passing through the pallets and within which rests the lens holding containers (not shown).
  • the pallets In order to move the pallets in the direction of travel uniformly and consistently and to reduce the vibration or other extraneous motion in thenon-travel directions, the pallets contain mechanical bias means such as a spring-loaded roller balls located on the side walls of the pallet body which cooperate with guide rails on the conveyor positioned to compress the mechanical bias means when the pallet is placed between the guide rails 60.
  • mechanical bias means such as a spring-loaded roller balls located on the side walls of the pallet body which cooperate with guide rails on the conveyor positioned to compress the mechanical bias means when the pallet is placed between the guide rails 60.
  • a drive means and a drive device may be used.
  • the pallet is first pushed against the guide rail by an L-shaped arm of the drive device. This constrains the pallet between the guide railand the L-shaped arm.
  • the pallet is then pulled in the direction of travel by the drive means via the L-shaped arm.
  • the conveyor system further comprises drive means64 which engages engagement means such as blind holes located in the sides of the pallets.
  • the drive means 64 are connected by mounting plate 66.
  • Drive means 64 contain a movable projection activated by an air cylinder of the type such as the Festo Pneumatic Cylinder, ADV-20-10-A, Hauppauge, N.Y., which at the pallet initial position enters the blind hole engagement means in pallet 16 to engage the drive means to the pallet.
  • Thedrive means 64 is powered by servo motor 65 to transport the pallets 16 smoothly and uniformly between or alternately along rails 60.
  • This servo motor is of the type as the Berger Lahr D314-006-L servo motor and the Alpha Gear Reducer SP75-M2 from Hano Electroteknik A-S, Denmark.
  • the projection is retracted into the drive means 64 and the drive means returned by servo motor 65 to the initial position to repeat the cycle.
  • the required precision of the drive and pallet system can be derived from the physical characteristics of the lens and package, the inspection system field-of-view, lens float and triggering sensor error. These requirements can be considered independently along the orthogonal X and Y axes, the X axis being the direction of travel.
  • a combined sensor error and lens float of 1.300 mm and package tolerance of 0.083 mm would require a fixture tolerance along the Y axis to be 0.300 mm.
  • the X axis there is no fixture tolerance consideration since the inspection is triggered by the package.
  • Inspection may take place at any of four camera locations 68. While four inspection locations are shown, only two may be needed to inspect the lens; that is, any two that are located on opposite rows of lenses on the pallets. Four inspection positions may be required, however, if it is desired to separately inspect different aspects of the lens, for instance an edge inspection and a center inspection or inspections at different depths of field.
  • a high resolution camera such as the Kodak Videk MegaPlus camera, is used to capture an image of the lens for inspection.
  • This camera has a field-of-view of 14.5 mm by 14.5 mm divided into a square array of 1024 pixels on a side, yielding a resolution of 14.1 ⁇ m by 14.1 ⁇ m.
  • FIG. 3 a side view of the apparatus described above is shown with like elements having like identification numerals.
  • strobe lamps 70 located on the side of the lens being inspected opposite the camera, and illuminating when a triggering means on the pallet activates a sensor, schematically shown at 71, responsive to the triggering means.
  • This lamp is of the type such as the Perceptics model LI004-VK strobe.
  • This strobe unit uses a xenon flash tube that emits between 3 and 5 joules of radiant energy over a time period of 40 ⁇ s duration.
  • the sensor for the package is the Keyence FS2-65 amplifier and FU-65 Fiber Optic Unit, sold by Keyenceof Fair Lawn, N.J.
  • a housing made of frame 72 and panels 74. These panels may be transparent in order for operators to view the operation of the mechanism inside the housing, or if necessary, opaqueto block ambient light and prevent specular reflections and deviations in uniformity to ambient light.
  • FIG. 3 also schematically shows image analysis means 77 that is connected to the cameras to receive the lens images therefrom and to analyze those images to determine whether the lenses are acceptable or unacceptable.
  • FIG. 4 an end planar elevational view of the apparatus described above is shown. In addition there is shown the path by which light travels from strobe lamp 70 through pallet 16 to the camera assembly
  • lenses In use, lenses would move past the inspection system at a speed of between 30 mm/sec to 50 mm/sec. With lenses on the pallet having a pitch of between 30 and 50 mm and preferably 35 mm, lenses can be inspected at the rate of about 1 per second. Although a time of 0.2 seconds required to grab the video frame is not limiting, processing time can reasonably be expected to be somewhat greater, on the order of 2.5 sec to 3.0 sec. In order to maintain the desired overall inspection rate, multiple processorsare used to alternately analyze the video images that are captured.

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  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Chemical & Material Sciences (AREA)
  • Analytical Chemistry (AREA)
  • Spectroscopy & Molecular Physics (AREA)
  • Eyeglasses (AREA)
  • Testing Of Optical Devices Or Fibers (AREA)
  • Investigating Materials By The Use Of Optical Means Adapted For Particular Applications (AREA)
  • Prostheses (AREA)
  • Eye Examination Apparatus (AREA)
  • Instruments For Viewing The Inside Of Hollow Bodies (AREA)
  • Measurement Of The Respiration, Hearing Ability, Form, And Blood Characteristics Of Living Organisms (AREA)
  • Medicines That Contain Protein Lipid Enzymes And Other Medicines (AREA)
  • Pharmaceuticals Containing Other Organic And Inorganic Compounds (AREA)
  • Developing Agents For Electrophotography (AREA)
  • Traffic Control Systems (AREA)
US08/681,639 1992-12-21 1996-07-29 Ophthalmic lens inspection system and method Expired - Lifetime US5745230A (en)

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Application Number Priority Date Filing Date Title
US08/681,639 US5745230A (en) 1992-12-21 1996-07-29 Ophthalmic lens inspection system and method

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Application Number Priority Date Filing Date Title
US99424992A 1992-12-21 1992-12-21
US54707395A 1995-10-23 1995-10-23
US08/681,639 US5745230A (en) 1992-12-21 1996-07-29 Ophthalmic lens inspection system and method

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US54707395A Continuation 1992-12-21 1995-10-23

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US (1) US5745230A (fr)
EP (1) EP0604180B1 (fr)
JP (1) JP3516709B2 (fr)
KR (1) KR100229563B1 (fr)
CN (1) CN1056693C (fr)
AT (1) ATE178405T1 (fr)
AU (1) AU674032B2 (fr)
BR (1) BR9305150A (fr)
CA (1) CA2111746C (fr)
CZ (1) CZ275993A3 (fr)
DE (1) DE69324221T2 (fr)
FI (1) FI935736A7 (fr)
GR (1) GR1002232B (fr)
HU (1) HU216248B (fr)
IL (1) IL107513A (fr)
MX (1) MX9400050A (fr)
NO (1) NO934710L (fr)
NZ (1) NZ250423A (fr)
UY (1) UY23690A1 (fr)
ZA (1) ZA939539B (fr)

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US5891371A (en) * 1994-06-10 1999-04-06 Johnson & Johnson Vision Products, Inc. Interactive control method for packaging control of time sensitive products
WO2000009980A1 (fr) * 1998-08-17 2000-02-24 Novartis Ag Module d'essai pour controler la presence eventuelle de defauts sur des pieces optiques
US6246062B1 (en) 1998-11-05 2001-06-12 Johnson & Johnson Vision Care, Inc. Missing lens detection system and method
US20040036858A1 (en) * 1999-02-02 2004-02-26 Roger Biel Lens checking apparatus
US6765661B2 (en) 2001-03-09 2004-07-20 Novartis Ag Lens inspection
US6835939B2 (en) 1998-11-05 2004-12-28 Ross, Iii Denwood F. Missing lens detection system and method
US20060232766A1 (en) * 2005-03-31 2006-10-19 Watterson Robert J Jr Methods of inspecting ophthalmic lenses
US7330579B2 (en) 2002-11-13 2008-02-12 Johnson & Johnson Vision Care, Inc. Automated inspection of tinted ophthalmic parts
US8322527B2 (en) * 2011-05-06 2012-12-04 Hon Hai Precision Industry Co., Ltd. Loading device for loading optical elements
WO2012166797A1 (fr) 2011-06-03 2012-12-06 Johnson & Johnson Vision Care, Inc. Inspection de lentilles ophtalmiques par rayonnement multiple
WO2012174131A1 (fr) 2011-06-16 2012-12-20 Johnson & Johnson Vision Care, Inc. Procédé de détermination de la longueur d'onde optimale pour l'inspection de lentilles ophtalmiques
WO2012177462A1 (fr) 2011-06-17 2012-12-27 Johnson & Johnson Vision Care, Inc. Système d'imagerie et d'inspection du bord d'une lentille ophtalmique
WO2021067218A1 (fr) * 2019-09-30 2021-04-08 Mettler-Toledo, LLC Détection de viande par rayons x
CN117960620A (zh) * 2023-11-30 2024-05-03 东莞三众电器科技有限公司 一种镜片的自动检测分选贴膜线
US20250242956A1 (en) * 2024-01-25 2025-07-31 Alcon Inc. Primary packaging line for ophthalmic articles
US12617569B2 (en) * 2025-01-23 2026-05-05 Alcon Inc. Primary packaging line for ophthalmic articles

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GR1002574B (el) * 1992-12-21 1997-02-06 Johnson & Johnson Vision Products Inc. Παλλετα για την υποδοχη και μεταφορα δοχειων οφθαλμικων φακων.
US5568715A (en) * 1994-05-31 1996-10-29 Johnson & Johnson Vision Products, Inc. Automated inspection system with transport and ejector conveyor
US5561970A (en) * 1995-06-21 1996-10-08 Johnson & Johnson Vision Products, Inc. Automated robotic lens load system
US5801822A (en) * 1997-02-06 1998-09-01 Pbh, Inc. Ophthalmic lens inspection system
US5818573A (en) * 1997-02-06 1998-10-06 Pbh, Inc. Opthalmic lens inspection system
US6577387B2 (en) 2000-12-29 2003-06-10 Johnson & Johnson Vision Care, Inc. Inspection of ophthalmic lenses using absorption
WO2003087755A1 (fr) * 2002-04-12 2003-10-23 Menicon Co., Ltd. Systeme et procede d'assistance destine a des lentilles de contact
DE10246483A1 (de) * 2002-09-30 2004-04-08 Carl Zeiss Jena Gmbh Linsenprüfgerät
JP4640055B2 (ja) * 2005-09-08 2011-03-02 富士フイルム株式会社 レンズ合否表示装置
JP2007315959A (ja) * 2006-05-26 2007-12-06 Fujinon Corp レンズ測定装置
CN102822655B (zh) * 2011-02-23 2016-01-20 联达科技检测私人有限公司 用于检验镜片的方法和装置
CN105115989B (zh) * 2015-10-09 2018-02-23 爱丁堡（南京）光电设备有限公司 一种隐形眼镜缺陷的自动检测设备及检测方法
KR200483832Y1 (ko) * 2015-12-15 2017-06-29 그레이트쿠오 테크놀러지 컴퍼니 리미티드 자동 순환식 검출 및 분류 장치
US10184916B2 (en) * 2016-01-15 2019-01-22 The Boeing Company Systems, methods, and devices for probe assemblies for variable curvature and variable angle configurations
CN109421963B (zh) * 2017-08-21 2020-11-03 晶硕光学股份有限公司 水平式装盒机自动投片验片机构
CN109421956B (zh) * 2017-08-21 2020-11-10 晶硕光学股份有限公司 水平式装盒机自动验片机构
JP3213909U (ja) * 2017-09-27 2017-12-07 欣柏 ▲黄▼ コンタクトレンズのレンズ検出装置
CN108982524B (zh) * 2018-08-22 2020-08-18 大智精创（厦门）科技有限公司 光学镜片自动化检测设备
HUE066161T2 (hu) 2019-09-17 2024-07-28 Alcon Inc Lencseellenõrzõ modul
US20250334480A1 (en) * 2021-10-27 2025-10-30 Transitions Optical, Ltd. Optical Article Inspection Apparatus and Method

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WO2012174131A1 (fr) 2011-06-16 2012-12-20 Johnson & Johnson Vision Care, Inc. Procédé de détermination de la longueur d'onde optimale pour l'inspection de lentilles ophtalmiques
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US11523618B2 (en) 2019-09-30 2022-12-13 Mettler-Toledo, LLC X-ray inspection of meat
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UY23690A1 (es) 1994-06-16
HU216248B (hu) 1999-05-28
EP0604180A3 (en) 1994-09-14
NO934710D0 (no) 1993-12-20
GR930100496A (el) 1994-08-31
KR940015472A (ko) 1994-07-21
ATE178405T1 (de) 1999-04-15
JP3516709B2 (ja) 2004-04-05
ZA939539B (en) 1995-06-20
HUT65900A (en) 1994-07-28
HU9303361D0 (en) 1994-03-28
JPH06229868A (ja) 1994-08-19
MX9400050A (es) 1994-06-30
DE69324221D1 (de) 1999-05-06
AU674032B2 (en) 1996-12-05
EP0604180B1 (fr) 1999-03-31
KR100229563B1 (ko) 1999-11-15
FI935736A7 (fi) 1994-06-22
IL107513A0 (en) 1994-02-27
EP0604180A2 (fr) 1994-06-29
NO934710L (no) 1994-06-22
AU5241293A (en) 1994-06-30
BR9305150A (pt) 1994-06-28
CN1090041A (zh) 1994-07-27
HK1003446A1 (en) 1998-10-30
NZ250423A (en) 1996-07-26
IL107513A (en) 1997-07-13
DE69324221T2 (de) 1999-09-02
CA2111746C (fr) 2005-04-05
GR1002232B (en) 1996-04-19
CZ275993A3 (en) 1996-04-17
FI935736A0 (fi) 1993-12-20
CA2111746A1 (fr) 1994-06-22
CN1056693C (zh) 2000-09-20

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